Flame denitration and reduction of uranium nitrate to uranium dioxide



June 26, 1962 W, H, HEDLEY ETAL 3,041,136

FLAME DENITRATION AND REDUCTION OF URANIUM 4 NITRATE TO URANIUM DIOXIDE l Filed April 8, 1960 2 Sheets-Sheet l 2 Sheets-Sheet 2 June 26, 1962 w.'H. HEDLr-:Y ETAL FLAME DENITRATION AND REDUCTION OF URANIUM NITRATE TO URANIUM DIOXIDE Filed April 8, 1960 United States Patent O 3,041,136 FLAME DENITRATIQN AND REDUCTION F URANIUM NHTRATE T0 URANIUM DOXIDE William H. Hedley, Kirkwood, and Robert I. Roehrs, St. Louis, Mo., and Courtland MJHenderson, Xenia, Ohio, assignors, by mesne assignments, to the United States of America as represented by the United States Atomic Energy Commission Filed Apr. 8, 1960, Ser. No. 21,071 5 Claims. (Cl. 23-14.5)

The present invention `deals with a process for converting aqueous uranyl nitrate to uranium `dioxide and an apparatus therefor. This process will hereafter be referred to as the flame process. The term aqueous uranyl nitrate will -be used to cover both uranyl nitrate hydrates and their solutions.

It is an object of the invention to accomplish the denitrification and reduction of aqueous uranyl nitrate in a single step, decreasing the costs of the operation substantially.

It is a further object of the invention to produce a unanium dioxide very well suited for conversion to uranium fluoride in that it reacts rapidly and completely with hydrogen fluoride to produce uranium tetrafluoride of very high purity. This tetrailuoride is a very important intermediate material for the production of uranium metal by reaction with calcium or magnesium. It is also a very useful intermediate in the production of uranium hexafluoride. This is the compound of uranium utilized in the diffusion process of enrichment in the isotope Uz35 It is also an object of this invention to produce uranium dioxide in a form that can be stored for long periods of time with substantially no deterioration by conversion to higher oxides through mere contact with air at ordinary temperatures. This occurrence would require further reduction before conversion could be made to the fluoride. Otherwise there would be contamination with oxy fluoride and other undesirable compounds.

Finally, it is an object of the invention to furnish an apparatus capable of converting aqueous uranyl nitrate to uranium dioxide smoothly, completely and continuously.

The present practice for converting aqueous uranyl nitrate to uranium dioxide normally requires three steps. The usual starting material is an aqueous solution, so the first step involves driving off sufficient water to form the molten hydrate. Next, sufficient heat is supplied to drive off the water of hydration and to decompose the uranium nitrate and obtain uranium trioxide. Finally, reduction t0 uranium dioxide is accomplished by passing either hydrogen or cracked ammonia through the heated trioxide. It is usual to perform each step in different equipment. e

The denitrification step may take place in a fluidized bed or in a batch reaction vessel. Further, the hydrated salt may be passed onto a bed of trioxide previously formed by a screw or other mechanical device. The reduction also may be carried out either in a fluidized bed, in a mechanically agitated bed, or in a moving bed. It is also possible to carry out the reaction lbatchwise under static conditions using thin layers of the trioxide in a reaction vessel.

The invention herein described can accomplish all three steps in a single operation, but for economic reasons it is preferable to concentrate a uranium solution to the molten hydrate stage before the process of this invention is applied. Therefore, the preferred embodiment of this invention replaces only two steps of the usual process.

The equipment for one workable means for effecting this one step reaction and the flow sheet are shown in the following drawings wherein:

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FIGURE 1 is a diagrammatic illustration of the apparatus; and

FIGURE 2 is a vertical sectional view of the reaction chamber proper.

Referring to FIGURE 1, the reaction chamber in which the dehydration, denitrification and reduction takes place is designated 101. A storage vessel for the aqueous uranyl nitrate is shown as 103. Positioned just below the reaction chamber 101 is the receiver 105. Cyclones 107 and 109, to remove solid products from the gases, are connected to the receiver 105 by pipes 106 and 108. A filter 111 is connected to cyclone 109 by pipeline 110. A gas cooler 113 is connected to the outlet of the filter 111. The outlet of the gas cooler 113 is connected to an absorber column 115 which communicates also to the atmosphere by pipe 116.

A rotary seal 119 communicates between the receiver 105 and a hopper 117. Similar rotary seals 121 and 123 connect the solid outlets of cyclones 107 and 109 to hopper 117. A boil down tank is connected to transfer pump 127, thence to storage vessel 103.

In operation, a reducing flame is produced in the reaction chamber 101 by the incomplete combustion of a hydrocarbon gas such as propane. To obtain the reducing flame propane is burned in a deficiency of air. A flame in which there is supplied less than 70% of the theoretically required air to burn the propane is Well suited to the process. Aqueous uranyl nitrate is admitted to the reaction chamber 101 from storage vessel 103. Some of the U02 produced drops into receiver 105; further amounts are separated from combustion gases by cyclones 107 and 109. The last traces of U02 are removed by the lter 111. The combustion gas then is cooled by the cooler 113 and nitric oxides absorbed in the absorber column 115 before the combustion gas exhausts to the atmosphere.

Referring to FIG. 2, a tubular shell 201 is 6 feet long and 34 inches in diameter. At the top of this shell an upper flange 203 is welded extending radially outward. Lower flange 205 is welded to the bottom of shell 201, extending radially outward and inward therefrom. The outer periphery of shell 201 is covered with pipe insulation 207. Inside of shell 201 are, in order, a first insulator layer 209, consisting of a layer of a few inches of a material of extra low thermal conductivity, such as high temperature service mineral wool Iblocks, a second insulator layer 211 consisting of a few inches of a material of low thermal conductivity such as re brick or alumina bubbles, and an inner refractory layer 213, made up of 6 rings of silicon carbide, one on top of the other in longitudinal alignment, each ring having one edge concavely rounded and one edge convexly rounded. This construction is employed to retain alignment. All insulating layers and the pipe insulation are supported by lower flange 205. 'I'he inner layer 213 defines a reaction chamber 213a which is open at its bottom to and communicates with receiver 105 (see FIG. 1). A cylindrical flame throat 301 is located within the upper portion of chamber 213a and is provided with a ange 301a extending outwardly therefrom near the top of the throat. Throat 301 is coaxial with shell 201 and is formed from graphite. The top of the flange 301e is flush with the top of the shell 201. This throat 301 is secured to and supported from an annular plate 303 which rests on and is fastened to upper flange 203 by bolts 305 and extends from throat piece 301 to the edge of insulation 207. A, smaller annular plate 307 rests on the larger plate 303 and is flush with the top of throat piece 301.

A burner assembly 309 comprises a double-walled metal cylinder 313 which` has a lower flange 315 extending outwardly from the base thereof, and has an air inlet line 317 leading into the volume between the walls of tween flange 321a and the bottom of shell 313.

shell 313; and a gas inlet line 31.9 passing through both l walls of shell 3ll3.l The burner assembly`3ll9 .is secured to plates 303 and 307 `by boltsl 311 passing through ange A cylindrical body 323 having an annular recirculation chamber325 therein and .surrounding a flame channel 341 conforms closely to the innerwall of shell 313 he- 327 pierce the top of body 323 and ports 329 pierce body 323 at its bottom.' 1

lA funnel tube 331 has its top aligned with and connected to the incurved end of the inner wall of shell 313 and forms a venturi 333 for the entrance of air from air inlet 317.l The funnel. tube' 331 forms with the upper incurving end of the innerwall'of the shell 313 and the flange 32M a gas inlet'chamber 333e` which communi cates with gas inletl line 3119. A conical ring 335 aligned with and connected to flange 321e forms with funnel tube 331 an orifice 337 for the entrance lof gas from. linlet 319; Airignition plug 339 passes through both walls of chamber member 323 into ame channel 341 i and when activated ignites the air-gas mixture. The

continuance of the llame in channel. 341 is monitoredby flame detector 343 essentially an ultraviolet sensitive device which penetrates into chamber 341. The function of chamber 325 is to allowthecirculation of. the. hot com- `bustion products to heat the combustion gases fed into l enter the chamber'213a. Nozzle 3fl5is water cooled and insulated (details not shown). The burner .is therefore built around the spray nozzle and the feed is introduced along the burner axis. p l l l Propane, vaporizedat 50 p.s.i.g. enters the apparatus through inlet tube 319; air enters through its inlet 317, also at 50 p.s.i.g. The gases ignite and pass into the chamber 213a through the area between chamber member 323 and the spray nozzle assembly 345. Meanwhile flame detector 343 detects the flame and releases a liquid through spray 345. At first the liquid is ordinary water, until a temperature in excess of 1500 F. is detected in the reaction chamber by a thermocouple (not shown). Then aqueous uranyl nitrate is admitted under pressure through a control valve (not shown). The droplets of aqueous uranyl nitrate enter the zone with the combustion gases, and are dried, denitrated and converted to U02 by the time they reach the bottom of the chamber. It has been found that with the pressures used, a length of about 6 feet is sufficient to complete the reaction.

The above-described unit is capable of converting aqueous uranyl nitrate to the dioxide in a single step, combining dehydration, denitrication and reduction. It is also capable of converting the molten hydrate to the dixoide in a single step. The properties of the uranium dioxide so produced are superior to those of the ordinary product, as will be shown later in the specification. The operation of the apparatus will now be described.

Prior to establishing a llame, nitrogen or other inert gas is used to purge the reaction chamber. The combustion mixture of gases is ignited -by depressing a start button on the flame detection unit. This sends current to a spark plug-type ignition rod located in the combustion area and also energizes two solenoid valves, one in the propane line and one in the air line. Opening of these valves allows a predetermined mixture of propane and air to ow through the burner and ignite by means of the spark from the ignition rod.

During ignition, the electronic network of the llame detection system is `bypassed for approximately sec- Ports` onrls` lf the llame is not established within that time, the

solenoid valve closes and can not be reopened for approximately seconds. However, if the flame is established the detection system is engagedl and holds lthe, feed gas solenoid open as long as it detects a flame. An excess of propane is fed .to the unit in order to simultaneously denitrate and reduce the uranyl nitrate to U02.A

The flow of combustion gases is then increased to a desired level and the llame is maintained automatically. The feed system is. constructed so'thateither water or aqeuous uranyl nitrate can be forced through the spray nozzle. Common practice is to ilow water through the system prior to introducing aqueous uranyl nitrate. There are two reasons for doing so. First, the Water .keeps the nozzle from becoming overheated during the preheat cycle. Second, if the flow of water is allowed to increase toa flow rate equal to the anticipated flow of the aqueous uranylnitrate, the unit will approach an equilibriuml condition and therefore the temperature in In this process, denitration .must take place almost'instantly, .but reduction to U02 of the powder formed takes place only as the particles travel down the .length of the 1 reactor. This was demonstrated by some early pilot-scale runs with inadequate-reduction in which the product con-` sisted predominantly of nitrate free UaO. `It is believed that there :are'four main factors which affect the conversion ofaqueous uranyl nitrate to U02 bythe flame process. They are droplet size, gas temperature, re ducing power of gases and residence time. Early experiments` resulted in 'USOS as a product `when using. a

lliquid droplet lsize of about 4t() microns or less, a generous excess of propane, an exit gas temperature of 1800 F. and a reaction chamber four inches in diameter by one foot long. Since the use of small particle size, excess propane and high gas temperature alone did not produce U02, it was decided that increased residence time in the reactor would be tried. Another reaction `chamber three feet long and live inches in diameter was therefore constructed. Operating with this longer chamber at the same gas and the liquid flow rates used previously, it was possible to produce U02 routinely with exit gas temperatures of approximately l800 F. In the apparatus used introduction of the feed parallel to the burner axis is also important. Trial runs were made employing nozzles which directed the spray into the flame in a direction perpendicular to the flame. In these runs the water was not all evaporated before it hit the opposite wall.

In order to prevent freezing of the aqueous urtanyl nitrate in the lines, Ia dilute liquid containing only 4.3 pounds of U/gallon (approximately 50 w/o uranyl nitrate) has been used as the -feed for most of the runs. However, three runs have been made using concentrated liquid containing 12.0 to 13.0 pounds of uranium per gallon (uranyl nitrate hexiahydrate contains 9.75 lbs. U/gal.).

This equipment and process has been found capable of using solutions of uranium nitrate containing up to 13 pounds of uranium per gallon. The preferred concentration is the highest concentration which can be used without plugging the nozzle, because this lowers the propane consumption per pound of uranium processed, and also the olf-gases from the process will be licher in byproduct nitrogen oxides which will make their recovery easier. The `apparatus described is able to handle gal/hr. of the l0 lbs. of U/gal. liquid. Heating and reduction of this quantity requires 380 pounds of pro pane and 6880 cu. ift. of 100 p.s.i.g. fair per hour. This produces a product U02 having unexpectedly desirable properties.

In evaluating the product obtained by the iiarne process, both chemical and physical properties have been rather exhaustively investigated.

EXAMPLE A series of runs were made in the pilot scale apparatus with 4a 3 foot chamber length and an exit gas temperature approximately 1800" P. During these runs aqueous ur-anyl nitrate was used in ia concentration ranging from 4.2 to 13.0 lbs. uranium per gallon. Aqueous uranyl nitrate containing 12.9 lbs. U/gal. was smoothly converted to \U02 iat the rate of 35.0 pounds of uranium'per hour, using 0.225 pound of propane per pound of uranium. Several batches were selected for tests. Since a large number of tests were to lbe made and the tests were lengthy, the tests were not repeated on every batch. Comparisons were made in each case with available U02 made by other processes.

In both cases efforts were made to cool the sample to room temperature before exposing it to ai-r. Because it is difficult to iget a sample lanalyzed without oxidation occurring, 95% free U02 is among the highest percentages ever analyzed. U02 used to make UF4 in ia completely enclosed, leakproof system would probably undergo less reoxidation.

Stability of flame process 'U02 against atmospheric oxidation- Samples of llame process U02, in layers less than 1/8 inch thick, were placed in open bottles and left exposed to the atmosphere for varying lengths of time. The results are shown in Table II.

vThe lamount of free U02 in the samples at time zero` is uncertain, but is known to have been less than 95%. This is believed to fall short of a 100% U02 product by reason of incomplete protection in the experimental apparatus Iduring original cooling. The oxidation which took place on standing was not excessive even under these very adverse conditions. In plant practice it would not be necessary to expose U02 -as thoroughly or for such long periods as this, and thus the amount yot oxidation which would take place under these circumstances should be considerably less.

U02 trace impurities-Samples of llame process U02 and Weldon Spring plant fluid bed U02 were analyzed spectrographically. The results of this analysis are listed below:

r two samples lare small in most cases.

6 TABLE III Spectrographic Analysis for Trace Impimties in U02 Flame proc- Fluid bed ess (p.p.m.) (p.p.m.) (Run D-15) 4 o.1 10 10 10 10 0.1o o.10 o.10 0.] 1 1 4 1 1 15 l5 1 15 eo 0.5 0. 5 so 2o 10 10 10 10 4 1o 20 2o 2o 1 2 2 2o 7c 3 1 20 20 70 50 The differences in concentration of impurities in these 'I'hose elements that appear to be higher in the llame process material (such as Cu and Zn) lare probably 'derived from com- Pponents `of the experimental iapparatus that require further engineering design.

The llame process U02 contains considerably less than the ppm. iron and 75 ppm. nickel which are the lonly limits for green salt. Trouble is not anticipated with any of the trace elements in this process.

Reactivity with hydrogen fluoride-'liable IV shows the HF concentrations, reaction completion times, and reaction temperatures used for llaboratory hyidrouorination evaluation of various `oxide samples. All data listed in this section were obtained from runs in a thermob-alance.

As shown in Table IV, the reactivity of llame process material with either anhydrous HF or 70% is exceptionally good. Times vfor complete reaction for several runs with this material have ranged from 7 to 13 minutes using anhydrous HF at 400 C. The reactivity of the fluid bed U02 is considered to be an average value for plant material run at 400 C.

The extreme reactivity of flame process material is 4greatly emphasized by noting its lower completion time with 70% HF when compared with that of fluid bed U02 that was treated with anhydrous HF. The 32 w/o HF run with llame process U02 shows that this material can utilize HF in almost any concentration, and that it should be compatible 'with the low excess HF process change being installed in the Weldon Spring plant, thus insuring the llowest possible raw materials cost for hydrotluorination.

Green salt properties- Samples of ame process U02 TABLE VII and `U02 from standard pot U03 were hydroiiuorinated P article Si e Distribution b Mzcromero ra h with 100 w/o HF at several diierent temperatures. The Z y g p analyses of the green salt produced are listed in Table V. 5 t Diameter equal to Orlcssthan l TABLE V Oxide source Green Salt Properties 95% 50% 5% Microns Micrims llicrmis Hydrolluorina- UO from std. ot UO tion temp. C. Flame Process (Run 2 p 3 15) AOI U02 D 22) 10 Fluid heli 100' 40' 2'5 DCICCIl uns# UH, In i1 fred 100 44 4.5 Peak Level percent percent AOI, WS., UH, g1

percent percent percent l This signifies, for example, that 50% of Run D-15 U02 has a particle 458 422 (l O8 3. 71 73 0 0. 83 2 77 73' s size equal to or smaller than 2.3M.

558 530 0.06 2.38 74. 008 4 37 72. 5 15 The above data'show that amehprocess-U02 has v irtu g (7)5 0. 00 3.18 73.2 0. 2 4.59 2.1i ally the same particle size distribution as high fired micro 6Go 647 0.21 L 35 7 1 8 0.21 3. g5 i218 nized material. The fluid bed U02 and the high fired U02 730 722 1. 50 1.00 75.1 2.07 4. 20 12.9 have very nearly the same particle size distributions, but

755 755 T50 1' 50 5-5 17-7 5-12 /4 both are much larger than those of micronized or flame 1 W.S. means water soluble and indicates UOgFs; AOI 20 process U02' The particle Slze dlstnbutlon of flame means ammonium oxalate insoluble and indicates unconvei-ted PYOCCSS U02 has been nearly Constant for au funs Checked, oxide. Uranium tetratliioride is often called green salt. with approximately 99 W/o of the material having a di.

The analyses show that low AOl green salt can be proamcter between 1/2 and l() microns. duced on a laboratory scale from both materials at tem- The average particle 4sizes of the same types of powder peratures up to 660 C. In the hydroiluorinations at tem- 25 as determined by Fisher Sub-Sieve Sizer are listed below: peratures of 72.2 C. and above, the AOIs increased due to thermal damage of the oxide. The llame process U02, TABLE VIII however, was less sensitive to thermal damage than was Average Particle Size as Determined by Fisher Sub-Sieve the standard material used for comparison. This seems Sizer @a n s S s Aveia o article r so able becau e powders compo ed of small particle Onde Source: me 1% 11121 icmns tend to be less susceptible to thermal damage. The inate- D 22 o 93 rial chosen for comparison is standard pot U03 which has Fme Proces? (Run T 0 60 1'08 been laboratory reduced to U02. The indicated lower Mlcfmzed hlgh med 243 susceptibility of iiame process U02 to thermal damage Fluld bed n 4'05 could be of real advantage in production by reducing the hlgh led number of lots of green salt rejected for high AOI. The results of these particle size measurements substan- The U02 samples used in these runs contained relatiate the conclusions drawn from Micromerograph meastively large amounts of U2O2, probably due to partial rememems, oxidation of U02 which had been exposed to the 'atmos- Densiti'es of cold pressed and sntered U02 compacts- Phol'o before oomploto Cooling The Presoll of 11h15 Usos 40 Samples of several types of U02 were cold pressed to form accounts for the relatively high water soluble contents of pellets which were red under a hydrogen atmosphere. the low temperature runs as compared with plant green The results listed in Table IX compare the densities of Salt. v the pellets produced with the maximum theoretical density Physical PFOPI'UGS--Tho Physlcaltpfoprties of the of UO2 (10.97 grains per cubic centimeter) and are the iiame process product to be discussed include U02 X-ray 45 highest attained by this method for each powder, at the analyses, U02 particle size, densities of cold pressed and conditions listed. sintered U02 compacts, U02 surface area, and tap density. The llame process, .the micronized high-fired and the U02 X-l'fy lf1f1 lyS@S-*X-fay analysis has been Used t0 standard Weldon Spring Huid-bed pellets were all fabridetermine the unit cell size, the strain, and the crystallite cated and red by the same procedure; therefore, their size for iiame process U02 and for lluid bed U02. These 50 densities should be directly comparable. values are listed in Table VI. The high-iired `screwereactor powder which had not TABLE VI been micronized was not iired as long nor at as high a temperature as the other samples. A longer, higher- U02 X-Rfly Analysis temperature ring of the material would be expected to increase the density of the product slightly, but not to the Flam@ extent that it would equal the micronized screw-reactor process Fluid U 02 (Run Bed U02 material, or llame-process material. The pellets evaluated "22) were cyiindiical in shape (0.4 in diameter by 0.4" high).

Unit ceu size A 5.4084 5. 40s G0 TABLE IX Strain, diinensionless Nono 0. 055 Crystaiiite size A 1,150 800 Denszties of cold pressed and szntered U02 c0mpacts.-

The unit cell size of both flame process U02 and fluid commu Percent bed U02 are the same within the limits of measurement. Firing Finne tion Ofmfix. The composition of the main phase of the flame process Onde Source mangi' mis/m U02 can definitely vbe established as being between UOMO sq. in. density and U02 01, probably closer to U02'20.

A statistical analysis of the X-ray data shows that the /iilln@ igrlI---d- 20 1y 700 50 96.1 strain trapped in the lattice of llame process U02 is not 20 17700 50 95.1 different from zero within 95% confidence limits. Based 70 Stlllard Weldon Sprintr Iluid- 2O 1 0 on this saine analysis, the crystallite size is 1150i10() m2352222.ggg;"r2-55657155 7 0 50 92'2 angstrorn units within 95% confidence limits. mllOlllZlDs) 16 1,635 100 91.7

U02 particle size-The Microinerograph particle size distribution of U02 producgd by Various methods is Shown 1 The 'temperatures listed were obtained by means of an optical pyrom eter which had been sighted on the molybdenum bout in which the in Table VII. pellets were fired.

Pellets produced yfrom lflame process U02 are slightly more dense than those produced from micronized high tired U02 and yet `did not require the further expensive particle size reduction.

The cost of micronizing one ton of U02 at a rate of 25 pounds per hour has been estimated at $1,466.26. While this cost might be lowered considerably if the rate could be increased to 50 or 75 pounds of U02 per hour, the cost of micronizing would still be many times larger than the flame process cost of converting uranyl nitrate l-iquor to U02. This cost could be completely saved in cases Where flame process U02 could be successfully substituted for micronized U02 in ceramic applications.

U02 surface area-Table X shows .the surface area of several U02 powders.

v TABLE X U02 Surface Area BET surface area OXlde SOUICS sq. meters/ gram The surface area (as determined by lthe BET krypton method) is approximately 2.6 -square meters per gram lfor the three samples of flame process U02 evaluated thus far.

e value determined for the fluid ybed U02 is slightly higher than that of ame process U02 even though its agglomerates are much larger than those of the llame process material. This is probably due to a large amount of surface area inside the uid ybecl U02 agglomerates, but the reason why uid bed U02 reacts so much more slowly than flame process U02 is unknown.

Tap Densiiy-(a)-U02.-The tap densities of several types of U02 are listed in Table XI.

TABLE XI U02 Tap Density Oxide source: Tap density, gJcc.

These numbers express the range of values which have been obtained for each material. The tap densities of the recently produced ilame process U02 have all been at the high end of the range listed. ments, it has been possible to raise the tap density of flame process U02 by changing operating conditions, and it is believed -that the upper limit has not yet been reached for this material.

(b)UF4.-Green salt was prepared by hydrolluorinating llame process U02 with 100i w/o HF batchwise in a laboratory furnace. The range of tap densities for this material and for plant UF4 are listed below:

TABLE XII Tap Density of Green Salt 'la density of Green Salt Source: U 4, gms/cc.

Flame Process U02 (laboratory hydrofluorinated to U'F4) 1.7-2.3 Screw Reactors 3.1-3.8

The recent values of tap density for llame process material have been at the high end of the range quoted. However, as in the case of tap density for iiame process U02, this is not considered to be the maximum attainable value.

Further experiments have been made in which thorium nitrate, thorium-uranium (5 weight percent uranium) nitrate and aluminum nitrate solutions have been treated In recent experi- 10 by this flame process. Analytical results are not yet available, but X-ray analysis indicates that the product from thorium nitrate is Th02 with no other phases detected.

It will be understood that this invention is not to be limited to the details given herein, but that it may be modiiied Within the scope of the appended claims. In particular the apparatus portion of the invention is not limited to the device described in detail. For example, it may be desirable to use multiple spray nozzles operating parallel to each other; it might also, under some circumstances, be advantageous to spray countercurrent to the hot combustion gases. High pressure would be required to form liquor droplets of sufficiently small size with a pressure atomizing nozzle, but a pneumatic atomizing nozzle could eliminate this need for high pressure.

In general an apparatus for the process must include, for satisfactory operation:

(1) A feed system;

(2) An insulated tubular reactor;

(3) A spray nozzle positioned parallel to the axis of the reactor;

(4) A burner for continuously burning a fuel gas-air mixture with less than the stoichiometric amount of air to produce hot reducing gases;

(5) An ignition system;

(6) A llame detection system;

(7) Devices for collecting the products.

It is intended that the invention include all variations in methods of assembling the apparatus.

What is claimed is:

1. A process for converting uranyl nitrate solution to uranium dioxide comprising spraying fine droplets of aqueous uranyl nitrate solution into a high temperature hydrocarbon llame, said ame being deficient in oxygen approximately 30%, retaining the feed in the llame for a siuicient length of time to reduce the nitrate to the dioxide, and recovering uranium dioxide.

2. A process according to claim 1 wherein the reducing flame is formed by air and an excess of propane.

3. A process according to claim 2 wherein the feed is introduced axially of the llame.

4. A process according to claim 3 wherein the flame is maintained at such a temperature that the temperature oi the exit gases is at least 1800 F.

5. A process according to claim 4 wherein the droplets of aqueous uranyl nitrate solution are no greater than 40 microns in diameter.

References Cited in the rile of this patent UNITED STATES PATENTS 2,267,720 -Cyr Dec. 30, 1941 2,613,137 Hellwig Oct. 7, 1952 2,735,745 Flook et al. Feb. 21, 1956 2,737,445 Nassen Mar. 6, 1956 2,757,072 Kapp et al. July 31, 1956 2,761,767 Perieres Sept. 4, 1956 2,903,334 Buckingham Sept. 8, 1959 FOREIGN PATENTS 661,685 Great Britain Nov. 28, 1951 707,389 Great Britain Apr. 14, 1954 OTHER REFERENCES Ser No. 379,872, Ebner (A.P.C.), published Apr. 27, 1943.

Katz: The Chemistry of Uranium, 1st edition, pages 303, 304, 307, McGraw-Hill Book Co., New York, N.Y. (1951).

Johnson et al.: Ceramic Bulletin, vol. 36, No. 3, page 116 (1957).

MCW-1429, pages 57-75, May 1, 1959. Y V

Hedley et al.: MCW-l451, pages 19-24, Aug. l, 1960. 

1. A PROCESS FOR CONVERTING URANYL NITRATE SOLUTION TO URANIUM DIOXIDE COMPRISING SPRAYING FINE DROPLETS OF AQUEOUS URANYL NITRATE SOLUTION INTO A HIGH TEMPERATURE HYDROCARBON FLAME, SAID FLALME BEING DEFICIENT IN OXYGEN APPROXIMATELY 30% RETAINING THE FEEDD IN THE FLAME FOR A SUFFICIENT LENGTH OF TIME TO REDUCE THE NITRATE TO THE DIOXIDE. AND RECOVERING UURANIUM DIOXDE. 